Plug counter, fracing system and method

ABSTRACT

A valve includes a tubular having at least one port, and a sleeve in operable communication with the tubular configured to uncover the at least one port in response to moving from a first position to a second position. The valve also has a seat that is configured to be passed a selected number of times without shifting the sleeve from the first position to the second position and is further configured to be passed one additional time after the selected number of times after shifting the sleeve from the first position to the second position.

BACKGROUND

In the Drilling and completion industries it is often desirable toaffect tools or formations at a great distance from a surface locatedfacility such as a rig. One example of an operation intended to affect aformation is a fracturing operation often referred to as fracing. Inorder to perform such an operation, hydraulic pressure is built within atubing string until the pressure exceeds formation capability forholding that pressure and fractures the formation. This type ofoperation is most effective if done in small incremental sections of aborehole for reasons related to control and distribution of fractures toserve the ultimate purpose of the borehole. Such purposes includehydrocarbon production and Carbon Dioxide sequestration, for example.

In the art, fracturing discrete locations of the borehole tends torequire a number of tools related to the pressuring of discretelocations. Where multiple fracturing locations are contemplated,generally a staged system must be built and administered correctly forit to work. One such system uses progressively larger seat diametersfrom the toe back to surface and then corresponding progressivelyincreasing diameter plugs or balls. While the system works well, it islimited by the number of different size balls that can be used.Tolerance is also required in any system (due to such things asirregular shape of tubing secondary to borehole irregularity), whichtherefore further limits the number of diameters usable in a particularsystem.

Since fracturing and other operations where it is desirable to isolatediscrete locations continue to become more prevalent and ubiquitous,alternate systems for accessing and manipulating the downholeenvironment are always well received.

SUMMARY

Disclosed herein is a plug counter. The plug counter includes a seatreceptive of a plug in a first position and capable of passing the plugin a second position. A first sleeve is in operable communication withthe seat and is longitudinally movable in response to movement of theseat between the first position and the second position. A second sleeveis in operable communication with at least one of the first sleeve andthe seat and is configured to index upon passage of the plug. A key isin operable communication with the seat and is configured to preventmovement of the seat to the second position after a selected number ofplugs have passed the seat. A third sleeve is in operable communicationwith the first sleeve, and a release member is in operable communicationwith the third sleeve and is configured to move the third sleeve withthe first sleeve after it is released.

Further disclosed is a method of fracing multiple zones. The methodincludes, running a plurality of plugs having substantially the samedimensions, indexing a plurality of plug counters with each of theplurality of plugs run, opening a fracing valve with one of theplurality of plug counters with the running of a first one of theplurality of plugs, and plugging one of the plurality of plug counterswith the running of the first one of the plurality of plugs. Alsoincluded is pressuring up and fracing a formation through the openedfracing valve, running more of the plurality of plugs, further indexingsome of the plurality of plug counters with each of the plurality ofplugs run, opening another fracing valve with the running of a secondone of the plurality of plugs, plugging one of the plurality of plugcounters with the running of the second one of the plurality of plugs,and pressuring up and fracing a formation through the opened fracingvalve.

Further disclosed is a fracing system which includes a plurality of samesized plugs and a plurality of clusters of fracing valves, wherein eachof the plurality of clusters is controllable by the plurality of samesized plugs to open at least one of the plurality of the fracing valveswithin each cluster and plugging an outlet of each cluster to allowfracing thereof separately from each of the other clusters of theplurality of clusters.

Further disclosed is a valve including a tubular having at least oneport, and a sleeve in operable communication with the tubular configuredto open the at least one port in response to moving from a firstposition to a second position. Also included is a defeatable seat inoperable communication with the sleeve, wherein the valve is configuredto pass a selected number of same sized plugs without shifting thesleeve from the first position to the second position and to pass a nextone of the same sized plugs after the selected number of same sizedplugs only after shifting the sleeve from the first position to thesecond position.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alikein the several Figures:

FIGS. 1-4 illustrate a cross sectional view of one embodiment of aportion of the tool disclosed herein in four different positions;

FIGS. 5-8 illustrate in partial transparent view a counter portion ofthe tool disclosed herein in four different positions corresponding tothe positions shown in FIGS. 1-4;

FIG. 9 is a perspective view of an alternate moveable seat substitutablein the tool;

FIG. 10 is a schematic view of a portion of an alternate housing of thetool 10 shown in FIG. 1;

FIGS. 11A-11C depict a cross sectional view of an embodiment of a plugcounter disclosed herein; and

FIG. 12 depicts a magnified cross sectional view of a telescoping portdisclosed herein.

DETAILED DESCRIPTION

Referring to FIGS. 1-4, a portion of plug counter tool 10 is illustratedin longitudinal cross section in four different positions to makeapparent not only its structural constituents but its operation as well.It is initially noted that the term “plug” as used herein is intended toencompass tripping balls, darts, and similar structures that can bepropagated through a borehole and/or tubing string to reach remotelocations therewithin. The plug counter tool embodiments disclosedherein facilitate the use of a single size plug for multiple actuationsequences. For example, where multiple fracture points are desired in aborehole, traditional fracturing would require a number of differentdiameter plugs used sequentially from smaller to larger as operationsprogress up the hole. With the tool embodiments described herein onlyone size plug is needed.

Referring directly to FIG. 1, an outer housing 12 includes a support 14to support a moveable plug seat 16, which in the case of FIG. 1 ispresented by a set of collet fingers 18. The support 14 and movable seat16 operate together to catch a plug 20 after which the plug is passed ordenied passage as discussed hereunder. The fingers 18 are supported bysupport 14 while the collet fingers are in a first position shown inFIG. 1. Support for the fingers 18 is dependent upon the position ofcollet 22, which is dependent upon the ability of a spring 24 to holdthe collet 22 in the first position shown in FIG. 1. More specifically,when a plug is seated in the seat 16 pressure can and will in operationbe built uphole of the plug. The spring rate of the spring 24 selecteddictates the amount of fluid pressure that can be resisted before thecollet 22 moves in a downhole direction and the fingers 18 becomeunsupported. The spring 24 is a compression spring and as illustrated isa coil spring. It will hold the collet 22 in the illustrated firstposition until a plug 20 engages the seat 16 and sufficient fluidpressure uphole of the plug overcomes the spring force of spring 24 andcompresses the same. As the spring 24 is overcome by fluid pressure, thecollet 22 moves in a downhole direction (to the right in the Figure) andmoves the fingers 18 off of the support 14 to a second position. Justdownhole of the support 14 is a plug passage recess 28 that will allowradial expansion of the fingers 18 (see FIG. 2) by an amount sufficientto allow passage of the plug 20 through the seat 16. After passage ofthe plug 20, fluid pressure equalizes across the seat 16 and the collet22 returns to the first position of FIG. 1 under the bias of the spring24.

Connected to the collet 22 is j-slot sleeve 30. Sleeve 30 moves axiallyof the tool 10 along with the collet 22. At a downhole end of thehousing 12, an anti-rotation sleeve 32 is attached to the housing 12.Sleeve 32 does not move relative to housing 12 in any way once the toolis assembled. Anti-rotation sleeve 32 includes one or more pin openings34 into which one or more pins 36 will be individually inserted. Eachpin 36 will thus be fixed to the anti-rotation sleeve 32 and extend intoan alignment groove 38 of which there will be one or more in the j-slotsleeve 30. The one or more pins 36 and respective alignment grooves 38ensure that the j-slot sleeve 30 is not rotatable but is permitted tomove only axially during operation of the tool 10. Upon movement of thecollet 22 induced by fluid pressure uphole of plug 20 as describedabove, the j-slot sleeve 30 will cycle back and forth axially of thetool 10.

Radially inwardly of the anti-rotation sleeve 32 and rotatable relativethereto is a helix sleeve 40 exhibiting a helical track 42 at an outsidesurface thereof. The helix sleeve 40 includes one or more j-slotfollowers 44 (one shown), which may be a part of the helix sleeve 40 ormay be a separate component that is engaged with the helix sleeve 40. Ineither event, the j-slot follower(s) 44 are configured to contact angledsurfaces 46 and 48 of a j-slot 50 (see FIG. 5) disposed at the j-slotsleeve 30 upon axial movement of the j-slot sleeve 30. Because followers44 are fixed to the helix sleeve 40, the helix sleeve 40 will moverotationally about the j-slot sleeve 30 as the followers 44 move alongeach angled surface 46 or 48. The impetus for this movement is the axialcycling of the j-slot sleeve 30 as described above. Each time a plug 20lands at the seat 16, thereby allowing pressure to build from upholeagainst the plug 20, and hence urging the collet 22 to a positionaligning the fingers 18 with recess 28, the followers 44 will contactand slide along one of the angled surfaces 46. This will cause ameasured or indexed rotation of the helix sleeve 40. Because the spring24 is compressed during this pressure induced axial movement, energy isstored that will be used to urge the followers 44 along the nextadjacent angled surface 48 pursuant to the j-slot sleeve 30 movinguphole under spring bias, causing another measured or indexed rotationof the helix sleeve 40. The spring 24 induces such movement only afterthe plug 20, against which fluid pressure had been applied, is released.

As the helix sleeve 40 rotates, a key 52 that is engaged with thehelical track 42 moves leftward in the drawing closer to an end 54 of akeyway 56. It is to be appreciated that although the illustratedembodiment moves in an uphole direction, the tool 10 can easily beconfigured to allow movement of the key 52 in a downhole direction byreversing the helix angle of the helical track 42 and reversing thesurface angles of surfaces 46 and 48. As illustrated in FIGS. 1 and 5,the key 52 is in a position that will allow the greatest number of plugsto pass before preventing passage of the next plug to be seated. FIGS. 4and 8 show the key in the position where the next plug to seat will notpass.

As configured the tool 10 will pass a number of plugs and then preventfurther passage of plugs because the helix sleeve 40 is prevented fromrotating by the contact between key 52 and an end 54 of keyway 56. Theprevention of rotation of the helix sleeve 40 correspondingly preventsthe j-slot sleeve 30 from cycling downhole sufficiently to allow thefingers 18 to reach the recess 28. Consequently the plug 20 cannot pass.This position is illustrated best in FIG. 8 where key 52 is at end 54and follower 44 is at surface 46 but it cannot slide on surface 46because the key will no longer allow rotation of the helix sleeve 40 dueto having run out of helical track 42. It is to be understood, then,that the maximum number of plugs that are passable through tool 10 arefixed by design during manufacture by the length of the helical track 42and the keyway 56. This is not to say however that this maximum numberof plugs is the only number of plugs that will be passable before a plugis denied passage. Rather, because the key is placable in the keyway 56as the tool is being run into the hole, at any point on the helicaltrack 42 that is exposed to the keyway 56, any number from the maximumnumber down to a single plug may be selected.

More specifically, the key 52 is a component of the tool 10 that isremovable and replaceable at any point along the keyway 56 where thehelical track 42 crosses the keyway 56. The helix sleeve 40 itself maybe marked to show how many plugs will pass before denying passage tomake it a simple operation in the field for a rig worker to place thekey in the keyway 56 to select a number of plug passages to facilitate aparticular operation. It should be noted that because of the highpressures generally encountered in the wellbore for operations relatedto seating plugs and the potential operations that might be effected bypressuring up on such a plug, for example fracturing at about 10,000psi, the key 52 should be robust in size and construction as it is, inthe end, the key that stops movement of the balance of the components.

Referring to FIGS. 9 and 10, an alternate embodiment of a portion ofplug counter tool 110 is illustrated. The embodiment operates similarlyto the tool 10 and identically operating components are not discussedagain. The tool is distinct in that a dog-based seat structure 122,having a plug seat 116, is substituted for the collet 22 in the FIG. 1embodiment. For clarity, numerals are mimicked in the 100 series. Innormal operation, dogs 118 function as do the fingers 18 from theprevious embodiment. The housing 112 is also distinct in that anadditional plug passage recess 150 is provided uphole of the support 114so that in reverse flow, the one or more dogs 118 can be moved intoalignment with the recess 150 to allow passage of one or more plugs 20in the uphole direction as part of a reverse circulation operation toremove the plugs 20 from the borehole. In order for the structure 122 tomove uphole, a plug that had been passed in normal operation of the tool110 is moved in reverse circulation into a seat 117 on the backside ofseat 116. The pressure of reverse circulation acts on the plug in thesame manner as in the original operation but in the opposite direction.A spring 152 is disposed uphole of the structure 122 and will becompressed against a top sub 154 at a selected force from fluid pressureon the plug. Movement of the structure 122 in the uphole directionmirrors that of movement in the downhole direction and aligns the dogs118 with the recess 128, which allows the plug to pass. While anembodiment could eliminate spring 152 and simply allow the structure 122to stay in the uphole position, including the spring 152 provides theadded benefit that the device will automatically revert to a functionalstate after passage of the plug in the uphole direction so that normaloperation of the tool 110 could be resumed if desired. Since reversecirculating has specifically been addressed with respect to thisembodiment, it is further noted that a dissolvable or disintegratableplug can be used thereby obviating the need for reverse circulation toremove the plug. Such dissolvable or disintegratable plugs can be usedin each embodiment of the invention, if desired.

Referring to FIGS. 11A-11C, an embodiment of a plug counter 210,disclosed herein, is illustrated that incorporates features of the tools10 and 110 therein. The tool 210 includes a helical counter arrangement214, similar to that disclosed in FIGS. 1-8 therefore the same referencecharacters are employed here. A plug seat 216 that is passable is alsoincluded. The plug seat 216 has one or more dogs 218 that are radiallyexpandable into a recess 226 in a tubular 230 upon longitudinal movementthat causes the dogs 218 to align with the recess 226. Although thisembodiment employs a single passable seat arrangement it should beunderstood that any passable seat arrangement could be employedincluding the plugs seat 16 described in FIGS. 1-4.

A primary difference in the plug counter 210 from that of tools 10 or110 is what occurs after the selected plug has caused the key 52 toprevent further longitudinal movements of the plug seat 226. Unlike theabove embodiments, in the embodiment of counter 210 the plug 20 is stillallowed to pass but only after failure of a release member 264 alsodisclosed herein as a force failing member (shown in FIG. 11C only)illustrated herein as shear pins.

To achieve this the plug counter 210 is configured to index the helicalcounter 214 each time one of the plugs 20 passes. Doing so entailsbuilding pressure against the plug 20, seated against the seat 216,until sufficient pressure is achieved to compress biasing member 24thereby allowing j-slot sleeve 30 to move relative to housing 12 (in arightward direction in the Figures). Since the recesses 226 are on thehousing 12, the plug 20 is allowed to pass the seat 216 when the j-slotsleeve 30 has moved to the point where the dogs 218 reach the recess226. As mentioned, each time one of the plugs 20 passes in this mannerthe helical counter 214 indexes.

After passing the selected number of plugs 20 to cause the helicalcounter to max out the key 52 prevents the J-slot sleeve 30 from movingat the same force that previously caused it to move. The forceincreases, in response to pressure increasing uphole of the seated plug20, until sufficient force is generated to fail a force failing member232 that holds the housing 12 in position relative to a tubular 236within which the housing 12 and all the other components discussedpreviously are positioned. The force failing member 232, shown herein asa shear pin, is shown in an already sheared condition and thus is in twoseparate pieces.

Longitudinal movement of the housing 12, made possible by failure of theforce failing member 232, allows the uncovering of one or more ports 240formed in a wall 244 of the tubular 236. These ports 240 when uncoveredare configured to provide fluidic communication between an inside 248and an outside 252 of the tubular 236. The ports 240 may, however, beplugged at least for a time as will be discussed further below. Theports 240 disclosed herein are fracing ports that allow fluid pumpedtherethrough to fracture a formation on the outside 252 of the tubular236.

Longitudinal movement of the housing 12 relative to the tubular 236 islimited by contact between an end 256 of the housing 12 and a shoulder260 of the tubular 236. Pressure is again allowed to increase resultingin increased forces in response to the housing 12 not moving. Anotherforce failing member 264 preventing additional travel between the J-slotsleeve 30 and the housing 12 fractures when sufficient force is applied.In this embodiment, this second force failing member 264 is the key 52itself. Once the key 52 is fractured the J-slot sleeve 30 is againallowed to move relative to the housing 12 until the plug seat 216aligns with the recess 226, thereby allowing the plug 20 to pass. Inorder to assure that the ports 240 are uncovered before the plug 20passes, the first force failing member 232 needs to be set to fail at alower force than the second force failing members 264.

The foregoing construction allows for any number of the plug counters210 to be employed for opening fracing ports 240 upon the running of aselected number of plugs 20. A fracing operation can also be carried outjust by altering the force need to fail one of the force failing member232 or 264 at one of the plug counters 210 downhole of the other plugcounters 210. The higher threshold need only be set to a pressure higherthan is needed to perform a fracing operation to assure that the fracingcan take place.

Having a plurality of the ports 240 above a plug counter 210 open canmake generating pressure sufficient to fail either force failing member232, 264 of the downstream plug counter 210 difficult. One way toaddress this concern is to plug the ports 240 with material that can beremoved at a desired later time. For example, a disintegratable material268 can be used to plug the ports 240 until the ports are exposed tofluid from the inside 248, for example. By fluidically sealing thedisintegratable material 268 with a rupturable material 272 on an outersurface thereof, the onset of disintegration can be delayed until thehousing 12 has been moved to thereby expose the disintegrable material268 to the reactive fluids on the inside 248. Alternately, thedisintegrable material 268 can be set to disintegrate in response toother stimulus such as changes in temperature and pressure for example.

Yet another method of removing a blockage from the ports 240 at adesired time is by using just the rupturable material 272 without thedisintegratable material 268. To do so one need set a pressure at whichthe rupturable material 272 ruptures at pressures greater than isrequired to fail the force failing members 232, 264 of all the plugcounters 210 that are to be opened for fracing and less than a pressureto fail a force failing member 232, 264 of the plug counter 210 beingused to plug the downstream end of the tubular 236.

Referring to FIG. 12, another embodiment of a port disclosed herein thatcould allow sufficient pressure to build to fail either force failingmember 232, 264 is illustrated at 280. The port 280 includes a nozzle284 with an opening 288 sized to generate backpressure in response toflow therethrough. A dimension of the opening 288 can be selected basedupon the number of the ports 284 that will be open at a given time andflow rates available to generate a backpressure sufficient to fail theapplicable force failing member 232, 264. The ports 284 in thisembodiment have three optional telescoping sleeves 292A, 292B and 292C,although any number of the sleeves 292 could be employed. Thetelescoping sleeves 292A, 292B and 292C are configured to extendrelative to one another such that a radially outer surface 296 isradially extendable in response to the sleeve 292A moving relative tothe sleeve 292B, and the sleeve 292B moving relative to the sleeve 292C.This configuration allows the sleeve 292A to move into sealing contactwith a wall (not shown) of a formation, for example, to facilitateinject of fluid pumped through the port 280, under pressure, directlyinto the formation. The telescoping sleeves 292A, 292B and 292C can beset to telescope at pressures less than what is required to fail eitherof the force failing members 232 or 264.

With such a set up a plurality of clusters of plug counters 210 could bepositioned along a single tubular 236. Working from the cluster furthestfrom surface first, each cluster could in sequence be opened and fracedthrough, all with the same sized plug 20.

While one or more embodiments have been shown and described,modifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustrations and not limitation.

The invention claimed is:
 1. A valve, comprising; a tubular usabledownhole having at least one port; a sleeve in operable communicationwith the tubular configured to uncover the at least one port in responseto moving from a first position to a second position; and a seat beingconfigured to be passed by plugs a selected number of times withoutshifting the sleeve from the first position to the second position andbeing further configured to be passed one additional time by anadditional plug after the selected number of times after shifting thesleeve from the first position to the second position.
 2. The valve ofclaim 1, wherein the valve is a treating valve.
 3. The valve of claim 1,wherein the valve is a fracturing valve.
 4. The valve of claim 1,wherein the plugs and the additional plug seatingly engagable with theseat have at least one dimension that is substantially the same.
 5. Thevalve of claim 1, wherein the plugs and the additional plug seatinglyengagable with the seat are substantially the same size in alldimensions.
 6. The valve of claim 1, wherein the plugs and theadditional plug seatingly engagable with the seat are balls.
 7. Thevalve of claim 1, wherein the at least one port is plugged for at leasta period of time after being uncovered by the sleeve.
 8. The valve ofclaim 7, wherein the at least one port is plugged with a disintegratablematerial.
 9. The valve of claim 7, wherein the at least one port isplugged with a rupturable material.
 10. The valve of claim 7, whereinthe at least one port includes a nozzle with an opening sized togenerate backpressure in response to flow therethrough.
 11. The valve ofclaim 7, wherein the at least one port includes at least one telescopingsleeve.
 12. The valve of claim 1, further comprising: a first forcefailing member, the valve being configured to allow the sleeve to movefrom the first position to the second position after failure of thefirst force failing member; and a second force failing member inoperable communication with the seat, the valve being configured suchthat the seat is passable after the sleeve has moved to the secondposition after the second force failing member has failed.
 13. The valveof claim 12, wherein the first force failing member fails at loads lessthan loads required to fail the second force failing member.
 14. Thevalve of claim 12, wherein the second force failing member is configuredto fail at loads above pressures needed to allow fracturing to takeplace.